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Reduction of iron ore fines by coal fines in a packed bed and fluidized bed apparatus—A comparative study

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Abstract

Reduction of iron ore fines by coal fines in packed and fluidized beds has been studied. The investigation includes study of the kinetic aspects of reduction, carbon and sulfur content of the direct reduced iron (DRI) produced, and metallography of the products. For both processes, the kinetic data fit the first-order reaction model. Reduction in a fluidized bed is much faster than in a packed bed system. In both cases, DRI contains a substantial amount of free carbon at the initial stages of reduction. At the later stages of reduction, the carbon present in the DRI is mainly in the combined state. For identical temperatures and particle sizes, reaction in fluidized bed is much faster compared to that in a packed bed. At any particular degree of reduction, sulfur content in DRI samples produced by fluidized bed reduction is always more than that of DRI samples produced by packed bed reduction. Scanning electron microscopy (SEM) micrographs reveal that metallic whiskers formed during reduction in packed beds only. These whiskers become more prominent at higher temperatures and longer times.

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Abbreviations

d :

average ore and coal particle size, mm

d p :

mean particle diameter, cm

E :

activation energy, kJ/mol

F :

air flow rate, L/min

Fe T i :

total iron in initial ore

Fe r T :

total iron in reduced mass

f c :

fixed carbon of DRI

g :

acceleration due to gravity, cm/s

h :

bed depth of the reduction mixture, mm

K :

ratio of weight of iron to that of O2 in ore

K :

slope of the line

k :

reaction rate constant, min−1

m :

coal : ore ratio in the reduction mixture

R:

gas constant, k cal/kg mol K

T :

absolute temperature, K

t :

time, min

t a :

time required to achieve a particular degree of reduction, min

U mf :

minimum fluidization velocity, cm/s

α :

degree of reduction

θ s :

density of solid, g/cm3

θ g :

density of air, g/cm3

μ :

viscosity of air, g/cm3 s

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Authors and Affiliations

  1. Metallurgical Engineering Department, Bangladesh University of Engineering and Technology, Dhaka, Bangladesh

    R. Haque (Associate Professor)

  2. Regional Research Laboratory, Bhubaneswar-751013, Orissa, India

    H. S. Ray (Director)

  3. Metallurgical Engineering Department, Indian Institute of Technology, 721302, Kharagpur, India

    A. Mukherjee (Professor)

Authors
  1. R. Haque
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  2. H. S. Ray
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  3. A. Mukherjee
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Haque, R., Ray, H.S. & Mukherjee, A. Reduction of iron ore fines by coal fines in a packed bed and fluidized bed apparatus—A comparative study. Metall Trans B 24, 511–520 (1993). https://doi.org/10.1007/BF02666434

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